Packaging laminate

ABSTRACT

Disclosed herein are compositions and methods related to a packaging laminate comprising: a first polymeric layer comprising a polypropylene copolymer or a high density polyethylene (HDPE) resin; and a second polymeric layer comprising a high density polyethylene (HDPE) resin or linear low density polyethylene (LLDPE) resin with a coextruded ethyl vinyl alcohol (EVOH) compatibilizer. Also disclosed herein are packaging containers formed of the packaging laminates.

This application is a continuation-in-part of U.S. application Ser. No.15/442,098, filed on Feb. 24, 2017, which claims the benefit of U.S.Provisional Application No. 62/299,235, filed on Feb. 24, 2016, and U.S.Provisional Application No. 62/322,886, filed on Apr. 15, 2.016, theapplications of which are incorporated herein by reference in theirentirety.

FIELD OF THE INVENTION

This invention relates to food packaging materials and more particularlyto a recyclable flexible packaging laminate.

BACKGROUND OF THE INVENTION

Coffee and other food products are packaged in bags formed from plasticwrap. Such plastic wrap must meet certain USDA and FDA standards. Inaddition, in order to protect food products from contamination andextend the shelf life of the food products, the plastic wrap must bedurable, printable, and capable of running on packaging machines.Finally, the plastic wrap should be recyclable once it has beendiscarded. None of the conventional films used in the market today arerecyclable or designed to extend the shelf life of food products.

Accordingly, a need exists for a plastic wrap material that meets allthe criteria outlined above.

SUMMARY OF THE INVENTION

In one aspect, disclosed herein are packaging laminates comprising afirst polymeric layer comprising a polypropylene copolymer; and a secondpolymeric layer comprising a low density polyethylene (LDPE), linear lowdensity polyethylene (LLDPE), and/or high density polyethylene (HDPE)resin with a coextruded ethyl vinyl alcohol (EVOH) compatibilizer.

Disclosed herein are packaging laminates of any proceeding aspect,further comprising a third polymeric layer positioned between the firstlayer and the second layer, wherein the third polymeric layer comprisesan HDPE resin.

In one aspect disclosed herein are packaging laminates comprising afirst polymeric layer comprising a high density polyethylene (HDPE)resin; and a second polymeric layer comprising a low densitypolyethylene (LDPE), linear low density polyethylene (LLDPE), and/orhigh density polyethylene (HDPE) resin with a coextruded ethyl vinylalcohol (EVOH) film barrier.

Also disclosed are packing laminates of any proceeding aspect, furthercomprising a third layer positioned between the first layer and thesecond layer, wherein the third polymeric layer comprises an HDPE resin.

In another aspect, the present invention is directed to a packagingcontainer, including a container body formed of a packaging laminate,wherein the packaging laminate includes: a first layer, constituting anouter layer of the packaging laminate, including a high densitypolyethylene (HDPE) resin and a second layer, constituting an, innerlayer of the packaging laminate, comprising a linear low densitypolyethylene (LLDPE) resin with a coextruded ethyl vinyl alcohol (EVOH)film barrier. In one embodiment, the HDPE includes 80 percent by weightof the first layer. In another embodiment, the first layer furtherincludes octene in an amount of 20 percent by weight of the first layer.In still another embodiment, the first layer further includes a calciumcarbonate filler. The first layer of the packaging laminate may have athickness of about 0.008 MIL to about 2 MIL. The second layer of thepackaging laminate may have a thickness of about 2 MIL to about 5 MIL.

In still another aspect, the present invention is directed to apackaging container, including a container body formed of a packaginglaminate, wherein the packaging laminate includes a print layer,constituting an outer layer of the packaging laminate, including a highdensity polyethylene (HDPE) resin, a core layer, constituting anintermediate layer of the packaging laminate, including a HDPE resin, alinear low density polyethylene (LLDPE) resin, a low densitypolyethylene (LDPE) resin, or combinations thereof, and a sealant layer,constituting an inner layer of the packaging laminate, comprising aLLDPE resin with a coextruded ethyl vinyl alcohol (EVOH) barrier, and adegassing valve formed in a wall of the container body. In oneembodiment, the degassing valve is removably attached to the wall of thecontainer body. In another embodiment, the print layer has a thicknessof about 0.008 MIL to about 2 MIL. In still another embodiment, theprint layer may have a first side and a second side, wherein the secondside is adjacent to the core layer, and wherein the second side iscapable of being printed thereon. In yet another embodiment, the HDPEincludes at least 40 percent by weight of the print layer.

In this aspect, each layer of the packaging laminate has a haze value ofabout 10 percent to about 60 percent. In another embodiment, thepackaging container may have a percentage of residual oxygen of about2.65 percent or less over a time period of 52 weeks. In still anotherembodiment, the sealant layer further includes a HDPE resin or a LDPEresin. The sealant layer may also further include from about 8 percentto about 20 percent weight of an ionomer.

In yet another aspect, the present invention is directed to a method ofrecycling the packaging container disclosed above by extruding thepackaging container to form an extruded plastic; pelletizing theextruded plastic; and combining the extruded plastic with an amount oflinear low-density polyethylene (LLDPE). In this embodiment, the amountof LLDPE is about 25 percent by weight to about 75 percent by weight.

The foregoing and other features and advantages of the invention will beapparent to those of ordinary skill in the art from the following moreparticular description of the invention and the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective drawing of a first embodiment of a packaginglaminate in accordance with the present invention.

FIG. 2 is a perspective drawing of a second embodiment of a packaginglaminate in accordance with the present invention.

FIG. 3 is a perspective drawing of a third embodiment of a packaginglaminate in accordance with the present invention.

FIG. 4 is a perspective drawing of a fourth embodiment of a packaginglaminate in accordance with the present invention.

FIG. 5 is a perspective drawing of fifth embodiment of a packaginglaminate in accordance with the present invention.

FIG. 6 is a perspective drawing of a sixth embodiment of a packaginglaminate in accordance with the present invention.

FIG. 7 is a graph showing shelf life data of packaging containers havinga packaging laminate in accordance with the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention is a packaging laminate that meets the criteriafor plastic wrap for food products. In one aspect, the packaginglaminate comprises two or more layers of a polyolefin film. It isunderstood and herein contemplated that the polymeric layers comprise,amongst other things one or more polymeric resins. Resins suitable forthe present invention are polyolefins which may include low densitypolyethylene (LDPE), linear low density polyethylene (LLDPE), highdensity polyethylene (HDPE), medium density polyethylene (MDPE), lowdensity polyethylene/high density polyethylene (LD/HDPE) mixes, ultrahigh molecular weight polyethylene (UHMWPE), cross-linked polyethylene(XLPE), polypropylene (PP) polymers, metallocene catalyzed polyolefinplastomer) resins. The resins of the present invention may either behomopolymers, co-polymers and/or ter-polymers of any one or more of theabove polymers. Examples of the latter are olefin-copolymers such aspolyethylene butylacrylate, polyethylene methacrylate,polypropylene-ethylene copolymers, and polyethylene vinyl acetate, andter polymers of polypropylene-ethylene co-polymer, LDPE, and HDPE.

Because the disclosed film comprises multiple polymeric layers, it isunderstood, that that the polymeric composition of each layer cancontribute to the physical attributes of the film given the intended useof the film. Accordingly, the composition of each layer of themultilayered polymeric film can be different or the same as any one ormore additional layers. In one aspect, each layer of the multilayeredpolymeric film can comprise different polyolefin resins. For example,the first polymeric layer can comprise one or more polypropylene,polypropylene co-polymers, polyethylene, LDPE, MDPE, HDPE, and/orLDPE/HDPE co-polymer resins or calcium carbonate and the secondpolymeric layer can comprise one or more HDPE, LLDPE, LDPE and/orLD/HDPE copolymer resins. Accordingly, in one aspect, disclosed hereinare packaging laminates comprising a first polymeric layer comprising apolypropylene copolymer (such as, for example a polypropylene-ethyleneor polypropylene-ethylene), LDPE, MDPE, HDPE and/or LD/HDPE co-polymers;and a second polymeric layer comprising a high density polyethylene(HDPE), linear low density polyethylene, (LLDPE), or low density (LDPE),and/or LD/HDPE co-polymer resin. Also disclosed are packaging laminatescomprising a first polymeric layer comprising a high densitypolyethylene (HDPE) resin; and a second polymeric layer comprising ahigh density polyethylene (HDPE), linear low density polyethylene(LLDPE), or tow density (LDPE), and/or LD/HDPE co-polymer resin.Furthermore, disclosed are packaging laminates comprising a firstpolymeric layer comprising a medium density polyethylene (MDPE) resin;and a second polymeric layer comprising a high density polyethylene(HDPE), linear low density polyethylene (LLDPE), or low density (LDPE),and/or LD/HDPE co-polymer resin. The resins employed in the disclosedpackaging laminates can be virgin resins or from reclaimed or recycledsources.

It is understood and herein contemplated that there can be more than onecomponent or polymer in the first and second polymeric layers. In oneaspect, the polymer comprising the greatest percentage weight of thepolymeric layer (i.e., the primary polymer) can be at least 1, 2, 3, 4,5, 6, 7, 8, 9, 10, 15, 16, 16.8, 17, 20, 25, 30, 33, 35, 40, 45, 50, 55,58.3, 60, 65, 66, 66.6, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 97,98, 99, or 100 percentage weight (or any amount in between) of the firstand/or second polymeric layer. For example, disclosed herein arepackaging laminates wherein the first polymeric layer comprises apolypropylene co-polymer (for example, a polypropylene-ethyleneco-polymer), wherein the polypropylene copolymer comprises between 35%and 55% weight, more preferably between 40% and 50% weight, and morepreferably 45% weight of the first polymeric layer. In anotherembodiment, for example, the first polymeric layer comprises HDPE,wherein the HDPE comprises between 40% and 100% weight (i.e., 40, 45,50, 55, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99,or 100% weight), more preferably between 60% and 100% weight, mostpreferably between 75% and 100% weight of the first polymeric layer. Inone aspect, the HDPE can be 80% weight of the first polymeric layer (forexample a first polymeric layer comprising 80% weight HDPE and 20%weight Octene). In another embodiment, the HDPE may be present in thefirst polymeric layer with other polypropylene resins, such as LDPEand/or MDPE. In this aspect, the HDPE may be present in the firstpolymeric layer in an amount of at least 40% by weight. In anotherembodiment, the HDPE is present in the first polymeric layer in anamount of at least 50% by weight. In still another embodiment, the HDPEis present in the first polymeric layer in an amount of at least 60% byweight.

Also, by way of example, disclosed herein are packaging laminateswherein the second polymeric layer comprises HDPE at 66.6% weight of thesecond polymeric layer. In a further embodiment, disclosed herein arepackaging laminates wherein the second polymeric layer comprises HDPE at58.3% weight of the second polymeric layer. Thus, for example disclosedherein are packaging laminates comprising a polypropylene co-polymerfirst polymeric layer and a second polymeric layer comprising HDPE atbetween 50 and 70% weight (such as, for example 58.3% or 66.6%) of thesecond polymeric layer. Also, disclosed herein are, for example,packaging laminates comprising a HDPE first polymeric layer and a secondpolymeric layer comprising HDPE at between 50 and 70% weight (such as,for example 58.3% or 66.6%) of the second polymeric layer.

As noted above, the disclosed polymeric layers can comprise additionalsecondary components including polymers in addition to the primarypolymer, including, but not limited to additionally one or more ofoctene, LLDPE, LDPE, MDPE, HDPE, LD/HDPE polymers, catalysts (forexample, metallocene), antiblock components, plastomers, ionomers (suchas, for example SURLYN®), tie, slip components, ethyl vinyl alcohol(EVOH), and EVOH compatibilizers (such as, for example Dow RETAIN® EVOHCompatibilizer). Accordingly, in one aspect, disclosed herein arepackaging laminates wherein the first polymeric layer further comprisesoctene, LLDPE, LDPE, MDPE, HDPE, and/or LD/HDPE co-polymer resins. It isunderstood and herein contemplated that the secondary components caneach individually comprise any percentage weight less than the primarypolymer including, but not limited to 0.2, 0.22, 0.3, 0.4, 0.5, 0.55,0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2,3, 4, 5, 5.9, 6, 6.5, 7, 8, 9, 10, 10.23, 11, 11.8, 12, 12.2, 13, 14,15, 16, 16.8, 17, 18, 19, 20, 25, 30, 30.2, 33, 35, 40, 45 percentweight. In one aspect, the first polymeric layer can comprise a HDPEresin of 16.8 percent weight and a LDPE resin of 6 percent weight of thetotal weight of the first polymeric layer (for example, a firstpolymeric layer comprising a polypropylene co-polymer (such as 45%polypropylene co-polymer) and 16.8% weight HDPE and 6% weight LDPE). Inanother embodiment, the first polymeric layer can comprise 80% weightHDPE and 20% weight octene. Also contemplated herein are polymericlayers comprising between 8% and 20% weight, more preferably between 10%and 14% weight, most preferably between 12% and 13% plastomer (forexample a polymeric layer (such as a second polymeric layer comprising12.2% weight plastomer)). Also contemplated herein are polymeric layerscomprising between 8% and 20% weight, more preferably between 10% and14% weight, most preferably between 10% and 12% ionomer such as SURLYN®(for example a polymeric layer (such as a second polymeric layercomprising 10.23% weight ionomer).

As previously noted, the polymeric layers can comprise additives such asantioxidants (for example, hindered phenols such as, for example,IRGANOX® 1010), phosphites (for example, IRGAFOS® 168)), U. V.stabilizers, cling additives (for example, polyisobutylene), antiblockadditives, slip agents, colorants, pigments, fillers such as calciumcarbonate, fire retardants, light and heat stabilizers, and extensionoils can also be included in the compositions of the present invention,to the extent that they do not interfere with the enhanced propertiesdiscovered by applicants. In-process additives, for example, calciumstearate, water, and fluoropolymers may also be used for purposes suchas for the deactivation of residual catalyst or for further improvedprocessability.

Optionally, compatibilizers such as a low molecular weight plastomer mayalso be used in the composition of the present invention. Acompatibilizer typically contains a functional group which is compatiblewith the primary polymer of the second polymeric layer such as, forexample, HDPE. Compatibilizers are well-known in the art and one skilledin the art would easily be able to recognize the type of compatibilizersuitable for the desired compositions, if needed. For example, a blendof a hydrogenated rigid block copolymer with a styrene-butadiene-styreneblock copolymer or other styrenic polymer may additionally comprise astyrene-ethylenebutene-styrene block copolymer as a compatibilizer.Additionally, a blend of a hydrogenated rigid block copolymer with apolycarbonate may additionally comprise a polyamide-maleic anhydridegrafted polyethylene as a compatibilizer. In one aspect, thecompatibilizer can be an ethyl vinyl alcohol (EVOH) compatibilizer, suchas, for example Dow RETAIN® EVOH Compatibilizer. Thus, in one aspect,disclosed herein are packaging laminates comprising a first polymericlayer comprising a polypropylene copolymer; and a second polymeric layercomprising a Low Density Polyethylene (LDPE), Linear low densitypolyethylene (LLDPE), and/or high density polyethylene (HDPE) resin witha coextruded ethyl vinyl alcohol (EVOH) compatibilizer. In anotheraspect, disclosed herein are packaging laminates including a firstpolymeric layer including a HDPE resin and a second polymeric layerincluding a Low Density Polyethylene (LDPE), Linear low densitypolyethylene (LLDPE), and/or high density polyethylene (HDPE) resin witha coextruded ethyl vinyl alcohol (EVOH) compatibilizer. It iscontemplated herein that the compatibilizer can comprise between 2 and15 percentage weight of the polymeric layer (for example 2, 3, 4, 5, 6,7, 8, 9, 10, 11, 12, 13, 14, or 15 percent weight), more preferablybetween 5 and 10 percent weight. Accordingly, disclosed herein arepackaging laminates wherein the second polymeric layer comprises acompatibilizer (such as, for example, Dow RETAIN® EVOH compatibilizer),and wherein the compatibilizer comprises at least about 5% weight of thesecond polymeric layer.

In one aspect, the compatibilizer is loaded in a 1:1 ratio with abarrier such as, for example, an EVOH barrier. In one aspect, disclosedherein are packaging laminates comprising packaging laminates comprisinga first polymeric layer comprising a polypropylene copolymer; and asecond polymeric layer comprising a Low Density Polyethylene (LDPE),Linear low density polyethylene (LLDPE), and/or high densitypolyethylene (HDPE) resin with a coextruded ethyl vinyl alcohol (EVOH)compatibilizer and an EVOH barrier. Also disclosed herein are packaginglaminates comprising a first polymeric layer comprising a high densitypolyethylene (HDPE) film; and a second polymeric layer comprising LowDensity Polyethylene (LDPE), Linear low density polyethylene (LLDPE),and/or high density polyethylene (HDPE) resin (for example, a lowdensity/high density polyethylene (LD/HDPE) film) with a coextrudedethyl vinyl alcohol (EVOH) film barrier. In another aspect, disclosedherein are packaging laminates comprising a first polymeric layercomprising a medium density polyethylene (MDPE) film; and a secondpolymeric layer comprising Low Density Polyethylene (LDPE), Linear lowdensity polyethylene (LLDPE), and/or high density polyethylene (HDPE)resin (for example, a low density/high density polyethylene (LD/HDPE)film) with a coextruded ethyl vinyl alcohol (EVOH) film barrier.Accordingly, disclosed herein are packaging laminates comprising between2 and 15 percentage weight of the polymeric layer (for example 2, 3, 4,5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 percent weight), morepreferably between 5 and 10 percent weight. For example, in one aspect,the packaging laminates can comprise a compatibilizer (such as, forexample, Dow RETAIN® EVOH Compatibilizer) and a barrier (for example, anEVOH barrier) wherein the compatibilizer and the barrier are each 5%total weight of the second polymeric layer.

In one aspect, the disclosed polymeric layers of the packaging laminatescan comprise a catalyst (such as, for example Metallocene). Typically,copolymers are hydrogenated to remove sites of unsaturation. Any methodof hydrogenation can be used and such methods typically include the useof metal catalysts supported on an inorganic substrate, such as Pd onBaSO4 (U.S. Pat. No. 5,352,744) and Ni on kieseiguhr (U.S. Pat. No.3,333,024), Additionally, soluble, homogeneous catalysts such assingle-site catalyst systems known in the art such Ziegler vanadium,hafnium and zirconium catalyst systems and metallocene catalyst systemsfor example, a constrained geometry catalyst systems or those preparedfrom combinations of transition metal salts of 2-ethylhexanoic acid andalkyl lithiums can be used. The copolymer hydrogenation can also beachieved using hydrogen and a heterogeneous catalyst such as thosedescribed in U.S. Pat. Nos. 5,352,744, 5,612,422 and 5,645,253. Thecatalysts described therein are heterogeneous catalysts consisting of ametal crystallite supported on a porous silica substrate.

Alternatively, the hydrogenation can be conducted in the presence of amixed hydrogenation catalyst characterized in that it comprises amixture of at least two components. The first component comprises anymetal which will increase the rate of hydrogenation and includes nickel,cobalt, rhodium, ruthenium, palladium, platinum, other Group VIIImetals, or combinations thereof. The second component used in the mixedhydrogenation catalyst comprises a promoter which inhibits deactivationof the Group VIII metal(s) upon exposure to polar materials, and isherein referred to as the deactivation resistant component. Suchcomponents preferably comprise rhenium, molybdenum, tungsten, tantalumor niobium or mixtures thereof.

The amount of catalyst (such as, for example, Metallocene) can bebetween 0.2 and 40 percent weight of the polymeric layer of thepackaging laminate, preferably between 5 and 33 percent weight. Forexample, the catalyst (such as, for example, Metallocene) can comprise0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 5.9, 6, 7, 8, 9,10, 11, 11.8, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25,26, 27, 28, 29, 30, 30.2, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40percent weight of a polymeric layer. It is understood and hereincontemplated that the percent weight of catalyst for each polymericlayer is independent of the other layer(s). For example, the catalyst(such as, for example Metallocene) can comprise 30.2 percent weight ofthe first polymeric layer and 5.9 percent weight of the second polymericlayer.

In one particular embodiment, the packaging laminate can comprise afirst polymeric layer comprising a polypropylene co-polymer and a secondpolymeric layer comprising an HDPE, LDPE, and/or LLDPE resin co-extrudedwith an EVOH barrier and an EVOH compatibilizer (such as Dow RETAIN®EVOH compatibilizer) as set forth in Table 1 below.

TABLE 1 Resin % Total in DNSPRET-DNP963-T4 Copolymer Polypropylene (3.8%45 Ethylene) Metallocene 30.2 High Density Polyethylene 16.8 Low DensityPolyethylene 6 Slip 1.2 Antiblock 0.8 % Total in EVOH-ION-DOW HighDensity Polyethylene 58.3 Plastomer 122 Tie 6.5 Metallocene 11.8 EVOH 5Dow RETAIN ® EVOH 5 Compatibilizer Antiblock 0.4 Slip 0.8

It is understood and herein contemplated that adjusting the percentageweight of individual components or changing components such asexchanging a plastomer for an ionomer) of either or both polymericlayers of the packaging laminate can change the packagingcharacteristics such as, for example, allowing for the ability to createa seam in a packaging container made of the packaging laminate at lowheat or can be separated without tearing the polymeric layer.Additionally, such changes can change production speed, reduce pressureneeded for recycling, reduce leaks, or increase puncture resistance. Forexample the use of an ionomer such as SURLYN® in the second polymericlayer allows for separation of a seam without tearing the packaginglaminate. Thus, for example, in one aspect, the packaging laminate cancomprise a first polymeric layer comprising a polypropylene co-polymerand a second polymeric layer comprising an HDPE, LDPE, and/or LLDPEresin co-extruded with an EVOH barrier and an EVOH compatibilizer (suchas Dow RETAIN® EVOH compatibilizer) as set forth in Table 2 below.

TABLE 2 Resin % Total in DNSPRET-DNP963-T4 Copolymer Polypropylene (3.8%45 Ethylene) Metallocene 30.2 High Density Polyethylene 16.8 Low DensityPolyethylene 6 Slip 1.2 Antiblock 0.8 % Total in EVOH-ION-DOW HighDensity Polyethylene 66.6 SURLYN ® 10.23 Tie 6.5 Metallocene 5.9 EVOH 5Dow RETAIN ® EVOH 5 Compatibilizer Antiblock 0.55 Slip 0.22

In another embodiment, the packaging laminate can include a firstpolymeric layer including HDPE and a second polymeric layer including aLLDPE resin co-extruded with an EVOH barrier and an EVOH compatibilizer(such as Dow RETAIN® EVOH compatibilizer).

It is understood and herein contemplated that there are structural andfunctional benefits to the orientation of the polymeric layers in thepackaging laminate. For example, in one aspect, disclosed herein arepackaging laminates comprising a first polymeric layer and a secondpolymeric layer, wherein the first polymeric layer is oriented to be onthe outside layer of the packaging laminate. For example, in oneembodiment, the packaging laminates comprise a first polymeric layercomprising a polypropylene co-polymer (such as a polypropylene and 3.5%ethylene co-polymer) and a second polymeric layer comprising HDPE,LLDPE, LDPE, and/or and LD/HDPE co-polymer. In another embodiment, thepackaging laminates comprise a first polymeric layer comprising apolypropylene co-polymer (such as a polypropylene and 3.5% ethyleneco-polymer) as well as LDPE and/or HDPE and a second polymeric layercomprising HDPE, LLDPE, LDPE, and/or and LD/HDPE co-polymer. In stillanother embodiment, the packaging laminates comprise a first polymericlayer comprising a HDPE or HDPE and Octene and a second polymeric layercomprising HDPE, LLDPE, LDPE, and/or LD/HDPE co-polymer. In anotherembodiment, the packaging laminates include a first polymeric layerincluding HDPE and an additional polyethylene, such as MDPE, and asecond polymeric layer including HDPE, LLDPE, LDPE, and/or LD/HDPEco-polymer. In still another embodiment, the packaging laminatescomprise a first polymeric layer, including HDPE and a second polymericlayer comprising LLDPE. In yet another embodiment, the packaginglaminates comprise a first polymeric layer comprising MDPE and a secondpolymeric layer comprising HDPE LLDPE, LDPE, and/or and LD/HDPEco-polymer. In one aspect, the first polymeric layer is on the outsideof the packaging laminate. In another aspect, disclosed herein arepackaging laminates wherein the first polymeric layer is oriented to beon the inside layer of the packaging laminate.

While in its simplest form the multilayered polymeric films disclosedherein comprises two layers. However, it is fully contemplated hereinthat the multilayered polymeric film can comprise 1, 2, 3, 4, 5, 6, 7,8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 29, 20, 25, 30, 35, 40, 45, or50 or more additional polymer layers. Thus, in one aspect, disclosedherein are multilayered polymeric films comprising 2, 3, 4, 5, 6, 7, 8,9, or 10 or more layers. For example, disclosed herein are multilayeredpolymeric films further comprising a third polymeric layer adjacent tothe second layer and on the opposite side from the first layer. In oneaspect, disclosed herein are packaging laminates, further comprising athird polymeric layer positioned between the first layer and the secondlayer. The third polymeric layer may include any type of polyethyleneresin. For instance, the third polymeric layer may include HDPE, LDPE,LLDPE, or combinations thereof.

For example, disclosed herein are packaging laminates comprising a firstpolymeric layer comprising a polypropylene copolymer; and a secondpolymeric layer comprising a high density polyethylene (HDPE) resin(including, but not limited to an HDPE resin with a coextruded ethylvinyl alcohol (EVOH) compatibilizer and/or an EVOH barrier), furthercomprising a third polymeric layer positioned between the first andsecond polymeric layer, wherein the third polymeric layer comprisesHDPE, LDPE, and/or LLDPE. Additionally, disclosed herein are packaginglaminates including a first polymeric layer including a HDPE resin and asecond polymeric layer including a LLDPE resin (including a LLDPE resinthat is coextruded ethyl vinyl alcohol compatibilizer (such as, forexample Dow RETAIN® EVOH compatibilizer and/or an EVOH film barrier)),further including a third polymeric layer positioned between the firstand second polymeric layer, wherein the third polymeric layer includesHDPE, LDPE, and/or LLDPE. Furthermore, disclosed herein are packaginglaminates comprising a first polymeric layer comprising a high densitypolyethylene (HDPE) resin or a medium density polyethylene (MDPE) and asecond polymeric layer comprising a low density/high densitypolyethylene (LD/HDPE) resin (including a LD/HDPE resin, that iscoextruded ethyl vinyl alcohol compatibilizer (such, as, for example DowRETAIN® EVOH compatibilizer and/or an EVOH film barrier)) furthercomprising a third polymeric layer positioned between the first andsecond polymeric layer, wherein the third polymeric layer comprisesHDPE, LDPE, and/or LLDPE.

It is understood and herein contemplated that the individual polymericlayers can comprise the same or different portion of the multilayeredpolymeric film and that the ratio of individual layers can be modifiedto achieve different visual effects. For example each layer of a twolayered film can comprise 50% of the film. Alternatively, one polymericlayer of a′two layered polymeric film can comprise 1, 2, 3, 4, 5, 6, 7,8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25,26, 27, 28, 29, 30, 31, 32, 33, 33.33, 34, 35, 35.065, 36, 37, 38, 39,40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57,58, 59, 60, 61, 62, 63, 64, 64.935, 65, 66, 66.66, 67, 68, 69, 70, 71,72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89,90, 91, 92, 93, 94, 95, 96, 97, 98, or 99 percent of the multilayeredfilm while the remaining layer comprises the remaining percentage of themultilayered film. For example, disclosed herein are packaging laminateswherein the first polymeric layer comprises about 35% of the thicknessof the laminate (for example, a packaging laminate with a 1.35 MIL firstpolymeric layer and a 2.5 MIL second polymeric layer). In anotheraspect, the thickness of the polymeric layer of the packaging laminatecan comprise about 20% of the thickness of the packaging laminate (forexample a packaging laminate with a 0.8 MIL first layer and a 4.0 MILsecond layer).

Similarly, in a three layered film each layer can comprise the sameportion (i.e., a ⅓ portion) of the film structure, have two layerscomprising the same portion of the film structure and the third layerbeing a different portion, or be independently proportioned. Forexample, it is disclosed herein that the first (i.e., the outer) layerand the third layer (middle layer) can each comprise 20% of themultilayered film (a total of 40%) while the second (outside layer)comprises the remaining 60% of the film. That is, any combination oflayer ratios can exist in the multilayered film, including, but notlimited to, an outer:middle:inner percentage of 5:90:5; 10:80:0;15:70:15; 20:60:20; 25:50:25; 30:40:30; 35:30:35; 40:20:40; 45:10:45;5:5:90; 10:10:80; 15:15:70; 20:20:60; 25:25:50; 30:30:40; 35:35:30;40:40:20; 45:45:10; 90:5:5; 80:10:10; 70:15:15; 60:20:20; 50:25:25;40:30:30; 30:35:35; 20:40:40; 10:45:45; 5:10:85; 10:15:75; 15:20:65;20:25:55; 25:30:45; 10:5:85; 15:10:75; 20:15:65; 25:20:55; 30:25:45;85:10:5; 75:15:10; 65:20:15; 55:25:20; 45:30:25; 85:5:10; 75:10:15;65:15:20; 55:20:25; 45:25:30; 5:85:10; 10:75:15; 15:65:20; 20:55:25;25:45:30; 10:85:5; 15:75:10; 20:65:15; 25:55:20; or 30:45:25 or anyother combination (such as, for example, 42.1:31.6:26.3).

Typically the thickness of each polymeric layer of the packaginglaminate is referenced in terms of MILs or gauge (GA, wherein 10 GA=0.1MIL). In one aspect, the thickness of each polymeric layer canindependently be from about 0.005 MIL to 6.0 MILs. That is eachpolymeric layer can be 0.005, 0.006, 0.007, 0.008, 0.009, 0.01, 0.02,0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6,0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.25, 1.3, 1.35, 1.4, 1.5, 1.6, 1.7, 1.8,1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2,3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6,4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, or 6.0MIL.

In one embodiment, the thickness of the first polymeric layer may beabout 0.005 MIL to about 3 MIL. In another embodiment, the thickness ofthe first polymeric layer may be about 0.008 MIL to about 2 MIL. Instill another embodiment, the thickness of the first polymeric layer maybe about 0.5 MIL to about 1.5 MIL. In yet another embodiment, thethickness of the first polymeric layer may be between about 0.8 MIL toabout 1 MIL.

The thickness of the second polymeric layer may be about 2 MIL to about6 MIL. For instance, the thickness of the second polymeric layer may beabout 2 MIL to about 5 MIL. In another embodiment, the thickness of thesecond polymeric layer may be about 2.5 MIL to 4 MIL. In yet anotherembodiment, the thickness of the second polymeric layer may be about 2.5MIL to about 3.5 MIL. In still another embodiment, the thickness of thesecond polymeric layer may be about 3.5 MIL to about 6 MIL.

For example, the first polymeric layer can be between 0.4 and 2.5 MILs(for example 0.8 MIL, 1 MIL, or 1.35 MIL) and the second polymeric layercan be between 2 and 4 MILs (for example 2.5 MIL, 3.5 MIL, or 4.0 MIL).In one aspect the first polymeric layer can be 1.35 MIL and the secondpolymeric layer can be 2.5 MIL. In another embodiment, the firstpolymeric layer can be between 0.5 and 0.8 MILs and the second polymericlayer can be between 2 and 4 MIL. For instance, the first polymericlayer can be 0.8 MIL and the second polymeric layer can be 4.0 MIL. Inanother embodiment, the first polymeric layer can be between 0.5 and 1MIL and the second polymeric layer can be between 2 and 3.75 MILs.

In an aspect comprising a further third polymeric layer (i.e., a middleor intermediate layer) the thickness of the third polymeric layer canbe, for example, between 0.4 and 4 MILS. In another embodiment, thethickness of the third polymeric layer may be about 0.8 MIL to about 3MIL. In still another embodiment, the thickness of the third polymericlayer may be about 1 MIL to about 2.5 MIL. In yet another embodiment,the thickness of the third polymeric layer may be about 1 MIL to about 2MIL.

Accordingly, also disclosed herein is a trilaminate packaging laminatewherein the first polymeric layer is 0.8 MIL to 1.25 MIL, the secondpolymeric layer is 2.0 MIL to 3.5 MIL and the third (i.e., the middle orintermediate) polymeric layer is 1 MIL to 3 MIL.

The thicknesses disclosed herein advantageously allow for reverseprinting on the packaging laminates. More specifically, due to thethinness of the first polymeric layer, printing may occur on the insideof the first polymeric layer such that any ink printing is protectedfrom the outside environment. Reverse printing helps prevent scuffing orscraping of the ink.

Any known methods for reverse printing may be utilized in accordancewith the present invention. For example, printing can be done by anyknown means using commercially available UV, Flexographic, UVFlexographic, water-based, solvent or other inks which result incomplete adhesion of ink to the label surface (i.e., the print layer ofthe packaging laminate). Generally, reverse printing involves having thefilm layer to be reverse printed undergo treatment so that the filmlayer will accept ink. The film layer may undergo any suitable surfacetreatment including, but not limited to, corona discharge treatment,plasma treatment, UV treatment, and/or electron beam treatment. Thesurface treatment helps make the film layer porous, which allows for thefilm layer to accept ink more readily. Then, a negative of the design tobe printed may be laminated onto the film layer such that the printingoccurs on the inside of the film layer (or the reverse side of the labelface). This process may be repeated for any layer of the packaginglaminate that will display a label or design.

The packaging laminates disclosed herein are in one aspect, intended foruse in packaging containers for perishable produces such as, forexample, coffee beans or ground, coffee. In another embodiment, thepackaging laminates disclosed herein are intended for use in packagingcontainers for pet food including dry pet food, semi-moist pet food, andmoist pet food. In this aspect, the packaging containers may include acontainer body formed of the packaging laminates of the presentinvention.

In one aspect, it is contemplated herein packaging containers comprisingthe packaging laminates disclosed herein further comprising a valve fordispensing a product into and/or out of the packaging container. In oneaspect the valve can be configured to allow for degassing (such as, forexample comprising a degassing filter). The valve may be formed in aside wall of the container body during molding or production of thepackaging container. In one embodiment, the valve may be permanentlyattached to the packaging container. In another embodiment, the valvemay be removably attached to the packaging container.

In one embodiment, the valve is formed of a polymeric material utilizedin one or more layers of the packaging laminates. For example, the valvemay be formed of a polymeric material utilized in the first polymericlayer. In this aspect, the valve may be formed of one or morepolypropylene, polypropylene co-polymers, LDPE, MDPE, HDPE, and/orLDPE/HDPE co-polymer resins. In one embodiment, the valve may be formedof MDPE, HDPE, or combinations thereof. In another embodiment, the valveis formed of HDPE. In still another embodiment, the valve is formed ofMDPE.

To address the additional stress that could be placed on the valve, itis understood and herein contemplated that the thickness of thepolymeric layers of the valve can be greater than the thickness of thepolymeric layers of the packaging laminate.

In one embodiment the packaging laminate and/or the valve of the presentinvention are recyclable. Upon disposal of the packaging container, thepackaging laminate and/or the valve of the present invention may berecycled. Indeed, the packaging laminate of the present invention and/orthe valve of the present invention can be recyclable to the same extentthat #2 HDPE film or #4 linear low density polyethylene (LLDPE) film isrecyclable.

In this aspect, the recycled packaging laminate and/or valve may bereprocessed into a form suitable for producing new packaging films,laminates, or valves. The recycled packaging laminate and valve mayundergo any known process for recycling film or plastic into newcomponents. In one embodiment, the packaging laminate/valve to berecycled may be put into a shredder to grind and/or shred the material.The shredded packaging laminate/valve may then be run through anextruder where the plastic is incited and mixed. As the plastic exitsthe extruder, the plastic is subjected to a water bath where the plasticis cooled. The recycled plastic is then pelletized and dried in a dryer.To ensure that all moisture escapes, the pellets are stored for about 3to 4 days to continue drying before post-blending occurs. The pelletsformed from the recycled packaging laminate valve may be used to producenew packaging components.

In one embodiment, during processing, the recycled packaging laminate iscombined with linear low-density polyethylene (LLDPE). In oneembodiment, the recycled packaging laminate may be combined with atleast 25 percent by weight of LLDPE. In another embodiment, the recycledpackaging laminate may be combined with at least 40 percent by weight ofLLDPE. In still another embodiment, the recycled packaging laminate maybe combined with at least 50 percent by weight of LLDPE. In yet anotherembodiment, the recycled packaging laminate may be combined with atleast 65 percent by weight of LLDPE. In another embodiment, the recycledpackaging laminate may be combined with at least 75 percent by weight ofLLDPE.

In one embodiment, as noted above, the recycled packaging laminate andthe LLDPE may be reprocessed into pellet form. The resulting pelletsformed from the recycled packaging laminate and the LLDPE demonstratesuperior melt flow rates, volatile contents, ash contents, and peakmelting temperatures such that the pellets can be used, for example, toproduce injection molded parts, such as valves for packaging containers,and new films and laminates.

In one embodiment, the resulting pellets have a melt flow rate of atleast 0.4 g/10 min. In another embodiment, the resulting pellets have amelt flow rate of at least 0.5 g/10 min. In still another embodiment,the resulting pellets have a melt flow rate of at least 0.6 g/10 min. Inyet another embodiment, the resulting pellets have a melt flow rate ofat least 0.7 g/10 min. The resulting pellets also show superior volatilecontents. In one embodiment, the resulting pellets have a volatilecontent of less than 0.05 percent. In another embodiment, the resultingpellets have a volatile content of less than 0.025 percent. In stillanother embodiment, the resulting pellets have a volatile content ofless than 0.01 percent. In yet another embodiment, the resulting pelletshave a volatile content of less than 0.005 percent. The resultingpellets also demonstrate superior ash contents. “Ash content,” as usedherein, refers to the amount of filler content in the material. In oneembodiment, the pellets have an ash content of less than 5 percent. Inanother embodiment, the pellets have an ash content of less than 3percent. In still another embodiment, the pellets have an ash content ofless than 1 percent. In yet another embodiment, the pellets have an ashcontent of less than 0.5 percent. Furthermore, the pellets demonstratesuperior peak melting temperatures as measured by differential scanningcalorimetry (DSC). For instance, the pellets have a peak meltingtemperature of less than 150° C., preferably less than 140° C., morepreferably less than 130° C., and even more preferably less than 120° C.

In another embodiment, the resulting pellets may undergo furtherprocessing to form new packaging films, laminates, or valves. Forinstance, the resulting pellets may be injection molded into packagingcomponents or formed into film or laminate materials. The packagingcomponents formed from the recycled packaging laminate and LLDPE showsuperior physical and mechanical properties. For instance, the packagingcomponents demonstrate superior flexural moduli. “Flexural modulus” or“flexural moduli” as used herein refers to the tendency for a materialto resist bending as measured in accordance with ASTM D638. In oneembodiment, the flexural modulus of the packaging components is lessthan 68,000 psi. In another embodiment, the flexural modulus of thepackaging components is less than 65,000 psi. In still anotherembodiment, the flexural modulus of the packaging components is lessthan 62,000 psi. In yet another embodiment, the flexural modulus of thepackaging components is less than 59,000 psi. The packaging componentsalso demonstrate superior tensile strength. As used herein, “tensilestrength” refers to the amount of stress a material can handle beforereaching permanent, non-elastic deformation as measured in accordancewith ASTM D638 or ASTM D882. In one embodiment, the tensile strength ofthe packaging components according to ASTM D638 is about 1020 psi toabout 2385 psi. In another embodiment, the tensile strength of thepackaging components according to ASTM D638 is about 1278 psi to about2130 psi. In still another embodiment, the tensile strength of thepackaging components according to ASTM D638 is about 1350 psi to about1980 psi. In yet another embodiment, the tensile strength of thepackaging components according to ASTM D638 is about 1500 psi to about1850 psi.

Moreover, the packaging components have superior notched izod impactstrengths. “Notched izod impact strengths” refer to the impactresistance of materials as measured in accordance with ASTM D256. In oneembodiment, the notched izod impact strength of the packaging componentsis about 5 ft. lb/in to about 12 ft. lb/in. In another embodiment, thenotched izod impact strength of the packaging components is about 6.4ft. lb/in to about 10.6 ft. lb/in. In yet another embodiment, thenotched izod impact strength of the packaging components is about 8 ft.lb/in to about 10 ft. lb/in. In still another embodiment, the notchedizod impact strength of the packaging components is about 8.5 ft. lb/into about 9.5 ft. lb/in. The packaging components also have goodelongation at yield values. “Elongation at yield,” as used herein, isthe strain that the material undergoes at the yield point, or thepercent change in length that occurs while the material is stressed toits yield point. In one embodiment, the packaging components may have anelongation at yield, of about 95 percent to about 218 percent. Inanother embodiment, the packaging components may have an elongation atyield of about 100 percent to about 195 percent. In still anotherembodiment, the packaging components may have an elongation at yield ofabout 110 percent to about 175 percent. In yet another embodiment, thepackaging components may have an elongation at yield of about 120percent to about 160 percent.

The recycled packaging laminate may also be recycled into new packaginglaminates and films. The packaging laminates and films produced from therecycled packaging laminate demonstrate superior physical and mechanicalproperties. For example, the newly formed packaging laminates and filmsdemonstrate superior tear strengths in the transverse direction (TD) andin the machine direction (MD). “Tear strength,” as used herein, refersto the measurement of a material's ability to resist tearing as measuredin accordance with ASTM D1922. In one embodiment, the newly formedpackaging laminates and films have a tear strength (TD) of about 548 gto about 1280 g. In another embodiment, the newly formed packaginglaminates and films have a tear strength (TD) of about 685 g to about1143 g. In still another embodiment, the newly formed packaginglaminates and films have a tear strength (TD) of about 750 g to about1050 g. In yet another embodiment, the newly formed packaging laminatesand films have a tear strength (TD) of about 800 g to about 910 g. Thenewly formed packaging laminates and films also have a tear strength(MD) of about 106 g to about 305 g. In another embodiment, the newlyformed packaging laminates and films have a tear strength (MD) of about133 g to about 248 g. In yet another embodiment, the newly formedpackaging laminates and films have a tear strength (MD) of about 150 gto about 221 g. In still another embodiment, the newly formed packaginglaminates and films have a tear strength (MD) of about 175 g to about210 g.

In another embodiment, the newly formed packaging laminates and filmshave a tensile strength (TD) according to ASTM D882 of about 872 psi toabout 2036 psi. In still another embodiment, the newly formed packaginglaminates and films have a tensile strength (TD) according to ASTM D882of about 1090 psi to about 1818 psi. In yet another embodiment, thenewly formed packaging laminates and films have a tensile strength (TD)according to ASTM D882 of about 1200 psi to about 1650 psi. In anotherembodiment, the newly formed packaging laminates and films have atensile strength (TD) according to ASTM D882 of about 1300 psi to about1500 psi. The newly formed packaging laminates and films also have atensile strength (MD) according to ASTM D882 of about 1356 psi to about3164 psi. In another embodiment, the newly formed packaging laminatesand films have a tensile strength (MD) according to ASTM D882 of about1695 psi to 2825 psi. In still another embodiment, the newly formedpackaging laminates and films have a tensile strength (MD) according toASTM D882 of about 1750 psi to about 2500 psi. In yet anotherembodiment, the newly formed packaging laminates and films have atensile strength (MD) according to ASTM D882 of about 1900 psi to about2300 psi.

The newly formed packaging laminates and films also have superiorelongation at yield values. In one embodiment, the formed packaginglaminates and films have an elongation at yield (MD) according to ASTMD882 of about 8 inches to about 18 inches. In another embodiment, theformed packaging laminates and films have an elongation at yield (MD)according to ASTM D882 of about 10 inches to about 16 inches. In stillanother embodiment, the formed packaging laminates and films have anelongation at yield (MD) according to ASTM D882 of about 11 inches toabout 14 inches. In yet another embodiment, the formed packaginglaminates and films have an elongation at yield (MD) according to ASTMD882 of about 12 inches to about 13.5 inches. The formed packaginglaminates and films also have an elongation at yield (TD) according toASTM D882 of about 0.39 inches to about 0.91 inches. In anotherembodiment, the formed packaging laminates and films have an elongationat yield (TD) according to ASTM D882 of about 0.45 inches to about 0.80inches. In still another embodiment, the formed packaging laminates andfilms have an elongation at yield (TD) according to ASTM D882 of about0.50 inches to about 0.60 inches.

Furthermore, the newly formed packaging laminates and films havesuperior Dart impact values. “Dart impact” refers to the amount ofimpact strength or toughness of the film as measured in accordance withASTM D1709. In one embodiment, the laminates and films have a dartimpact of about 50 g/mil to about 245 g/mil. In another embodiment, thelaminates and films have a dart impact of about 75 g/mil to about 219g/mil. In still another embodiment, the laminates and films have a dartimpact of about 100 g/mil to about 200 g/mil. In yet another embodiment,the laminates and films have a dart impact of about 100 g/mil to about150 g/mil. The newly formed packaging laminates and films also havesuperior haze values. For example, the newly formed packaging laminatesand films have haze values according to ASTM D1003 of about 10 percentto about 70 percent. In another embodiment, the newly formed packaginglaminates and films have haze values of about 15 percent to about 60percent. In still another embodiment, the newly formed packaginglaminates and films have haze values of about 20 percent to about 50percent.

In addition to being recyclable, the packaging laminates of the presentinvention provide extended shelf lives for contents within the packagingcontainers. For instance, the packaging laminates preserve the shelflife of perishable produces such as, for example, coffee beans or groundcoffee. As used herein, “shelf life” refers to the length of time forwhich a perishable item remains usable and fit for consumption. Withoutbeing bound by any particular theory, it is believed that the packaginglaminates of the present invention regulate the internal atmosphere ofthe packaging container and prevent oxygen transmission into thecontainer. Indeed, in one embodiment, the percentage of residual oxygenwithin packaging containers having a packaging laminate according to thepresent invention over a time period of 52 weeks is about 2.65 percentor less, preferably about 1.85 percent or less, more preferably about1.15 percent or less, and even more preferably about 0.95 percent orless.

In one embodiment, when the packaging laminates of the present inventionare utilized in a packaging container, the contents of the packagingcontainer have a shelf life of about 6 weeks or greater. In anotherembodiment, the contents of the packaging container have a shelf life ofabout 18 weeks or greater. In still another embodiment, the contents ofthe packaging container have a shelf life of about 24 weeks or greater.In yet another embodiment, the contents of the packaging container havea shelf life of about 35 weeks or greater. In still another embodiment,the contents of the packaging container have a shelf life of about 52weeks or greater.

The packaging laminate of the present invention can be filled and sealedby conventional vertical and/or horizontal, automated bagging machines.

EXAMPLES Example 1 Inventive Packaging Laminates

FIG. 1 illustrates a first embodiment of a packaging laminate 10 inaccordance with the present invention. The packaging laminate 10 has twolayers including an outside layer 12 and an inside layer 14. When thepackaging laminate is used to form a food package for holding foodproducts, the inside layer 14 is positioned next to the food product,and the outside layer 12 is the outside of the food package.

The outside layer 12 of the packaging laminate 10 is a PP copolymer filmhaving a thickness in the range 0.4 mil-2.5 mils. The inside layer 14 ofthe packaging laminate 10 is a high density polyethylene (HDPE) filmwith a coextruded EVOH film barrier and EVOH compatibilizer (such as DowRETAIN® EVOH compatibilizer). The inside layer 14 has a thickness in therange 1.25 mils-6.0 mils. One particularly advantageous embodiment ofthe packaging laminate 10, shown in FIG. 1, has an outside layerthickness of 1.35 mils and an inside layer thickness of 2.5 mils.

The properties of the packaging laminate 10, shown in FIG. 1, are setforth in Table 3 below.

TABLE 3 Description Units Results Method Tensile at Break TD Grams 2500ASTM D882 Tensile at Break MD Grams 4500 ASTM 0882 Elongation at Break-% 720 ASTM TD 0882 Elongation at Break- % 740 ASTM MD 0882 ElmendorfTear (TD) Grams 700 ASTM 0882 Elmendorf Tear (MD) Grams 200 ASTM 0882Oxygen Transmission cc/100 in2/day 0.23 ASTM 03985

With respect to the terms used in Table 3 above and Tables 4 and 5below:

-   -   a. “Tensile at Break TD” specifies the force applied in grams in        order to break the packaging laminate in its machine direction        (MD).    -   b. “Tensile at Break MD” specifies the three applied in grams in        order to break the packaging laminate in its transverse        direction (TD).    -   c. “Elongation at Break TD” specifies the percentage of        elongation of the packaging laminate at break in its TD.    -   d. “Elongation at Break MD” specifies the percentage of        elongation of the packaging laminate at break in its MD.    -   e. “Oxygen Transmission” specifies the amount of oxygen in cubic        centimeters transferred through a 100 in.² area of the packaging        laminate in a 24-hour period.    -   f. “Water Vapor Transmission” specifies the amount of water        vapor in grams transferred through a 100 in.² area of the        packaging laminate in a 24-hour period.

FIG. 2 illustrates a second embodiment of a packaging laminate 110 inaccordance with the present invention. The packaging laminate 110 hasthree layers including an outside layer 112 which is a PP copolymerfilm, an inside layer 114 which is an HDPE with a coextruded EVOH filmbarrier and EVOH compatibilizer (Such as Dow RETAIN® EVOHcompatibilizer), and a middle layer 116 which comprises HDPE. When thepackaging laminate 110 is used to form a food package for holding foodproducts, the inside layer 114 is positioned next to the food productand the outside layer 112 is the outside of the food package.

The outside layer 112 of the packaging laminate 110 having a thicknessin the range 0.4 mil-2.5 mils. The inside layer 114 has a thickness inthe range 1.25 mils-6.0 mils. The middle layer 116 of the packaginglaminate 110 is having a thickness in the range 0.8 mil-4.5 mils.

FIG. 3 illustrates a third embodiment of a packaging laminate 210 inaccordance with the present invention. The packaging laminate 210 hastwo layers including an outside layer 212 comprising HDPE or HDPE andOctene (for example, 80% weight HDPE and 20% weight Octene) and aninside layer 214 comprising HDPE with a coextruded EVOH film barrier andEVOH compatibilizer (such as Dow RETAIN® EVOH compatibilizer). When thepackaging laminate 310 is used to form a food package for holding foodproducts, the inside layer 214 is positioned next to the food product,and the outside layer 212 is the outside of the food package.

The outside layer 212 of the packaging laminate 210 is a HDPE or HDPEand Octene film having a thickness in the range 0.4 mil-2.5 mils. Theinside layer 214 of the packaging laminate 210 is a LD/HDPE film with acoextruded EVOH film barrier. The inside layer 114 has a thickness inthe range 1.25 mils-6.0 mils. One particularly advantageous embodiment,shown in FIG. 3, has an outside layer thickness of 0.80 mils and aninside layer thickness of 4.0 mils.

The properties of the packaging laminate 210, shown, in FIG. 3, are setforth in Table 4 below.

TABLE 4 Description Units Results Method C.O.F. Outside Kinetic 0.25ASTM D1894 C.O.F. Inside (Seal Side) Kinetic 0.15 ASTM D1894 Tensile atBreak TD Grams 3500 ASTM D882 Tensile at Break MD Grams 3200 ASTM 0882Elongation at Break-TD % 400 ASTM 0882 Elongation at Break-MD % 150 ASTM0882 Oxygen Transmission cc/100 in2/day 0.1 ASTM 03985 Water VaporTransmission gm/100 in2/day 0.1 ASTM F1249

In Table 4 above:

-   -   a. “C.O.F. Outside” means the coefficient of friction for the        outside surface of the outside layer 212 of the laminate 210.    -   b. “C.O.F. Inside (Seal Side)” means the coefficient of friction        for the inside surface of the inside layer 214 of the laminate        210.

FIG. 4 illustrates a fourth embodiment of a packaging laminate 310 inaccordance with the present invention. The outside layer 312 of thepackaging laminate 310 is a PE film having a thickness in the range 0.4mil-2.5 mils. The inside layer 314 of the packaging laminate 310 is alow density/high density polyethylene (LD/HDPE) film with a coextrudedEVOH film barrier. The inside layer 314 has a thickness in the range1.25 mils-6.0 mils. The middle layer 16 of the packaging laminate 310 isa HDPE film having a thickness in the range 0.8 mil-4.5 mils. Oneparticularly advantageous embodiment of the packaging laminate 10, shownin FIG. 1, has an outside layer thickness of 1.25 mils, an inside layerthickness of 2.0 mils, and a middle layer thickness of 1.5 mils. In analternative embodiment, the thickness of the inside, outside, and middlelayers, can be 0.8 mils (i.e., 80 GA), 2.0 mils, and 1.5 mils,respectively.

The properties of the packaging laminate 310, shown in FIG. 4, are setforth in Table 5 below.

TABLE 5 Description Units Results Method Tensile at Break TD Grams 4800ASTM D882 Tensile at Break MD Grams 4500 ASTM 0882 Elongation at Break-% 750 ASTM TD 0882 Elongation at Break- % 700 ASTM MD 0882 OxygenTransmission cc/100 in2/day 0.24 ASTM 03985 Water Vapor gm/100 in2/day 8ASTM Transmission F1249

FIG. 5 illustrates a fifth embodiment of a packaging laminate 410 inaccordance with the present invention. The outside layer 412 of thepackaging laminate 410 is a HDPE film having a thickness of 100 ga (or 1MIL). The outside layer 412 underwent reverse printing such that the inkprinting is on the inside of the outside layer 412. The inside layer 414of the packaging laminate 410 is a white LLDPE resin co-extruded with anEVOH barrier and an EVOH compatibilizer (such as Dow RETAIN® EVOHcompatibilizer). The inside layer 414 has a thickness of 3.5 MIL. Thepackaging laminate 410 also included 2 parts solventless adhesive.

The properties of the packaging laminate 410, shown in FIG. 5, are setforth in Table 6 below.

TABLE 6 Description Units Results Method Thickness Mils 4.5 ASTM D5947C.O.F. Outside Kinetic .2 ASTM D1894 C.O.F. INSIDE Kinetic .2 ASTM D1894(Seal Side) Tensile at Break MD Grams 700 ASTM D882 Oxygen Transmissioncc/100 in2/day .25 ASTM D3985 Opacity % 75 ASTM D6216 Dwell Time Seconds.5 Seal Strength Grams 350 ASTM F88/ F88M-09 Seal Pressure PSI 40 SealTemp Farenheit 275 Lamination Bond 1 Grams 400 40 ASTM D 1876-01

As can be seen from Table 6, the packaging laminate 410 demonstratedexcellent hot tack and seal strength and excellent oxygen and moisturebarrier properties. The packaging laminate 410 also met FDA requirementsfor direct and indirect food contact.

FIG. 6 illustrates a sixth embodiment of a packaging laminate 510 inaccordance with the present invention. The outside layer 512 of thepackaging laminate 510 is a HDPE film having a thickness of 100 ga (or 1MIL). The outside layer 512 underwent surface printing. The inside layer514 of the packaging laminate 510 is a white LLDPE resin co-extrudedwith an EVOH barrier and an EVOH compatibilizer (such as Dow RETAIN®EVOH, compatibilizer). The inside layer 514 has a thickness of 3.5 MIL.The packaging laminate 510 also included 2 parts solventless adhesive.

The properties of the packaging laminate 510, shown in FIG. 6, are setforth in Table 7 Below.

TABLE 7 Description Units Results Method Thickness Mils 4.5 ASTM D5947C.O.F. Outside Kinetic .2 ASTM D1894 C.O.F. INSIDE Kinetic .2 ASTM D1894(Seal Side) Tensile at Break MD Grams 7000 ASTM D882 Oxygen Transmissioncc/100 in2/day .25 ASTM D3985 Opacity % 75 ASTM D6216 Dwell Time Seconds.5 Seal Strength Grams 3500 ASTM F88/ F88M-09 Seal Pressure PSI 40 SealTemp Farenheit 275 Lamination Bond 1 Grams 400 400 ASTM D 1876-01

As can be seen from Table 7, the packaging laminate 510 demonstratedexcellent hot tack and seal strength and excellent oxygen and moisturebarrier properties. The packaging laminate 510 also met FDA requirementsfor direct and indirect food contact.

Example 2 Shelf Life Studies

Packaging containers having packaging, laminates according to thepresent invention were tested for residual oxygen over a time period of0 weeks to 52 weeks. The packaging laminate was composed of a firstpolymeric layer including HDPE and a second polymeric layer including aLLDPE resin co-extruded with an EVOH barrier and an EVOH compatibilizer(such as Dow RETAIN® EVOH compatibilizer). Each of the packagingcontainers contained 3 pounds of coffee beans. A Flexis MC valve wasalso attached to each packaging container. The results of the testingare set forth in Table 8 below. FIG. 7 also shows the residual oxygenpercentage over the 52 week time period.

TABLE 8 T = 2 T = 6 T = 18 T = 24 T = 35 T = 52 T = 0 Wks Wks Wks WksWks Wks # of 2 6 6 6 6 6 6 Bags Aver- 1.36% 0.53% 1.15% 1.63% 1.83%0.92% 2.63% age O₂ # O₂ 0 0 0 1 2 1 3 Fail- ures

As can be seen from the results, the residual oxygen content within thepackaging container remained at or below 3 percent over the course of 52weeks. Thus, the packaging containers having packaging laminatesaccording to the present invention were able to preserve perishableproducts, such as coffee beans, for at least 52 weeks.

Example 3 Evaluating Recyclability of the Packaging Laminates inProducing Pellets and Injection Molded Parts

The following example demonstrates the recyclability of the packaginglaminates according to the present invention. As shown below, thepackaging laminates of the present invention may be recycled andreprocessed into pellets, which may be used to produce injection moldedparts (such as valves for packaging containers) having superior physicaland mechanical properties.

Materials & Equipment

The following materials were evaluated for recyclability:

Control Film LLDPE Control Film (Monolayer) No additives, layers, print,or color Test Film 1 1.35 mil copolymer with polypropylene (Test 1)Solvent based inks and adhesion 2.5 mil DOW recycle ready EVOH LLDPEInventive Test 80 ga HDPE (high molecular weight) Film 2 1.25 mil HDPE(Test 2) Solvent based inks and adhesions 2 mil DOW recycle ready EVOHLLDPE

The following recycle system was used to evaluate the recyclability ofthe materials; Grinder with ⅜′ screen; desiccant dryer; pelletextrusion; Arburg Injection Machine with a ASTM part mold; InstronUniversal Testing Machine; Tinius Olsen. Extrusion Plastometer; KonicaMinolta CM-3600d spectrophotometer; and Metler Toledo Density.

Pellet Processing

Each of the films were reprocessed into pellet form. During, processingof the pellets, test films 1 and 2 were each, combined with linearlow-density polyethylene (LLDPE). For the first run, test films 1 and 2were each used in an amount of 25% by weight and combined with 75% byweight LLDPE. For the second run, test films 1 and 2 were each used inan amount of 50% by weight and combined with 50% by weight LLDPE. Table9 shows the extrusion temperature and pressure data.

TABLE 9 Test 1 Test 1 Control 25% 50% AVG. Melt Temperature ° F. 396 398195 AVG. Pressure PSI 137 272 350 Test 2 Test 2 Control 25% 50% AVG.Melt Temperature ° F. 396 390 393 AVG. Pressure PSI 137 125 161

The resulting pellets were then run through an extrusion plastometer at190° C. to measure the melt flow. The resulting measurements shown inTable 10 are displayed in units of g/10 min.

TABLE 10 Test 1 Test 1 AVG. Melt Flow Rate Control (0%) 25% 50% 190° C.0.758 0.582 0.389 Test 2 Test 2 AVG. Melt Flow Rate Control (0%) 25% 50%190° C. 0.758 0.674 0.512

The resulting pellets were also measured for volatile content using anAZI Computrac moisture analyzer (for 10 grams of air-dried pelletexposed to 160° C. for 10 minutes). Table 11 below shows the averagevolatile percentage.

TABLE 11 Test 1 Test 1 Control 25% 50% AVG. Volatile % at 160° C.0.0038% 0.0184% 0.0246% Test 2 Test 2 Control 25% 50% AVG. Volatile % at160° C. 0.0038% 0.0273% 0.0301%

The pellets were farther measured for Ash percentage using aThermo-Scientific FB1415M Muffle Furnace at 800° C. for 5 minutes. Table12 below sets forth the average Ash percentage for the pellets.

TABLE 12 Test 1 Test 1 Control 25% 50% AVG. Ash % 0.12% 1.69% 2.57% Test2 Test 2 Control 25% 50% AVG. Ash % 0.10% 1.76% 2.86%

The peak melting temperature of the pellets was measured usingdifferential scanning calorimetry (DSC). Table 13 sets forth the peakmelting temperatures of the pellets.

TABLE 13 Test 1 Test 2 Control 50% 50% Peak Melting 122.19° C. 176.07°C. 145.01° C. Temp.

Injection Molding Processing

Pellets of test films 1 and 2 and pellets of the control film wereinjection molded into ASTM test parts to measure flexural modulus,tensile strength, and notched Izod. The processing conditions did notchange from one variable to the other.

A three-point bend test was used to measure the flexural modulus on allvariables. The test was performed in accordance to ASTM D790. Theresults are shown below in Table 14.

TABLE 14 Test 1 Test 1 Control 25% 50% AVG. Flexural Modulus (psi) 5840553151 72310 Test 2 Test 2 Control 25% 50% AVG. Flexural Modulus (psi)58405 61926 67480

All variables were tested for tensile strength at yield which is thestress a material can handle before reaching permanent deformation. Thetest was performed in accordance to ASTM D638. The tensile test resultsare shown below in Table 15.

TABLE 15 Test 1 Test 1 Control 25% 50% AVG. Tensile @ Yield (psi) 17041510 1781 Test 2 Test 2 Control 25% 50% AVG. Tensile @ Yield (psi) 17041878 1954

Using the injection molded impact bars, izod impact testing inaccordance to ASTM D256 was performed on all variables. The specimenswere notched in the center of the test bar before being subjected to the1.22 pound pendulum. The notched izod tests are shown in Table 16 below.

TABLE 16 Test 1 Test 1 Control 25% 50% Notch Izod (ft- 8.50 9.75 10.61lb/in) Test 2 Test 2 Control 25% 50% Notch Izod (ft- 8.5 10.49 10.88lb/in)

Example 4 Evaluating Recyclability of the Packaging Laminates inProducing New Films

The following example demonstrates the recyclability of the packaginglaminates according to the present invention. As shown below, thepackaging laminates of the present invention may be recycled andreprocessed into new films and laminates having superior physical andmechanical properties.

Materials

The following film materials were evaluated for recyclability andreprocessability:

% Total in Virgin and Resin Control Virgin Base Film Make UpPolyethylene Octene 60 Metallocene 30 Antiblock2/Slip1 10 V1 Base FilmMake Up Copolymer Polypropylene 45 (3.8% Ethylene) Metallocene 30.2 HighDensity Polyethylene 16.8 Low Density Polyethylene 6 Slip 1.2 Antiblock0.8 Inventive V2 Base Film Make Up High Density Polyethylene 66.6 Surlyn10.23 Tie 6.5 Metallocene 5.9 EVOH 5 Dow Retain EVOH 5 CompatibilizerAntiblock 0.55 Slip 0.22

The above-noted films were blended for production into new films. Thefilm material blends were as follows:

Virgin Material Blend

-   -   Octene 60%/Metallocene 30%    -   Antiblock2/Slip1 10%

0% PFE Repro at 50% with 50% Virgin Material Blend

-   -   Octene 30%/Metallocene 15%    -   Antiblock2/Slip1 5%    -   0% Repro PFE Material 50%

V2 25% PFE Repro at 50% with 50% Virgin Material Blend

-   -   Octene 30%/Metallocene 15%    -   Antiblock2/Slip1 5%    -   V2 25% Repro PFE Material 50%

V2 50% PFE Repro at 50% with 50% Virgin Material Blend

-   -   Octene 30%/Metallocene 15%    -   Antiblock2/Slip1 5%    -   V2 50% Repro PFE Material 50%

V1 25% PFE Repro at 50% with 50% Virgin Material Blend

-   -   Octene 30%/Metallocene 15%    -   Antiblock2/Slip1 5%    -   V1 25% Repro PFE Material 50%

V1 50% PFE Repro at 50% with 50% Virgin Material Blend

-   -   Octene 30%/Metallocene 15%    -   Antiblock2/Slip1 5%    -   V1 50% Repro PFE Material 50%

Procedure & Equipment

The equipment was started and all heat profiles and air flow werestabilized. The material % feed was prepared to meet the blends notedabove. Once confirmed and recorded, the trials began and samples wereproduced for the following blends: Virgin Material Blend; 0% PFE Reproat 50% with 50% Virgin Material Blend, V2 25% PFE Repro at 50% with 50%Virgin Material Blend; 50% PFE Repro at 50% with 50% Virgin MaterialBlend; V1 25% PFE Repro at 50% with 50% Virgin Material Blend; and V150% PFE Repro at 50% with 5.0% Virgin Material Blend. The film sampleswere prepared for testing at a thickness of 1.5 mil and a 3.2 BUR.Testing was completed per the ASTM requirements.

The following equipment was utilized during the film production: MaguireMaterial Blender; Kirion™ 40 Extrusion Line; 80 mm die with a blow-upratio of 3.2 with a lay flat of 16 inches (bubble diameter of 10.1inches); and a tower cage and roller system.

Table 17 below shows the extruder conditions during processing of thefilms.

TABLE 17 Virgin 0% V1-25 V1-50 V2-25 V2-50 Process Conditions Blower Air40 40 40 40 40 40 Ring % Width Set (in) 20 20 20 20 20 20 Basket Diam-18.22 18.22 18.22 18.22 18.22 18.22 eter (in) Cage Height 9 9 9 9 9 9(in) Extruder Conditions Rot Speed 146.8 146.8 146.8 146.8 146.8 146.8RPM Load % 54 49 53 49 47 50 Melt Temp ° F. 387 397 395 397 397 398 MeltPressure 1593 1412 1418 1419 1453 1518 (psi) Difference 1539 1412 14181419 1453 1518 Pressure (psi) Set (ft/m) 103 99 94 94 94 94 TemperatureProfile Feeder 375 373 373 373 373 373 Extruder Bar- 375 385 385 385 385385 rel 1 Extruder Bar- 384 394 395 395 395 395 rel 2 Extruder Bar- 385405 398 400 404 399 rel 6 Blown Film 400 400 400 400 400 400 Die 1 BlownFilm 400 400 400 400 400 400 Die 2 Blown Film 400 400 400 400 400 400Die 3

Results of Film Production

The film material blends were recycled and produced into new films. Thephysical and mechanical properties of the newly formed films are shownin Table 18 below.

TABLE 18 Results Assessment Virgin 0% V1-25% V1-50% V2-2% V2-50%Thickness 0.00163 0.00143 0.00176 0.00175 0.00157 0.00164 ASTM D6988(in.) Tear Strength 426.67 177.47 317.17 391.33 206.67 301.67 (MD) ASTMD1922 (g) Tear Strength 927.67 913.63 912.83 926.67 871.43 831.33 (TD)ASTM D1922 (g) Tensile 1583.84 2259.91 1728.79 1856.95 2046.28 1872.36Strength (MD) ASTM D882 (psi) Tensile 1456.24 1453.85 1488.64 1502.291454.78 1513.01 Strength (TD) ASTM D882 (psi) Elongation at 13.24 13.2213.44 13.36 13.22 13.29 Yield (MD) ASTM D882 (in.) Elongation at 264.8264.4 268.8 267.2 264.4 265.8 Yield (MB) ASTM D882 (%) Elongation at0.67 0.65 0.61 0.51 0.50 0.45 Yield (TD) ASTM D882 (in.) Elongation at13.4 13 12.2 10.2 10 9 Yield (TD) ASTM D882 (%) Dart Impact 175 100 110100 100 50 ASTM D1709 Haze ASTM 15.43 11.30 39.23 57.20 40.87 69.53D1003

As can be seen from the above results, the films formed from therecycled packaging laminates of the present invention demonstratedsuperior physical and mechanical properties. As such, the packaginglaminates of the present invention are able to be fully recycled intonew packaging laminates and films.

The embodiments and examples set forth herein were presented in order tobest explain the present invention and its practical application and tothereby enable those of ordinary skill in the art to make and use theinvention. However, those of ordinary skill in the art will recognizethat the foregoing description and examples have been presented for thepurposes of illustration and example only. The description as set forthis not intended to be exhaustive or to limit the invention to theprecise form disclosed. Many modifications and variations are possiblein light of the teachings above.

What is claimed is:
 1. A packaging container, comprising: a containerbody formed of a packaging laminate, wherein the packaging laminatecomprises: a first layer, constituting an outer layer of the packaginglaminate, comprising a high density polyethylene (HDPE) resin, whereinthe first layer comprises a first side and a second side, and whereinthe second side of the first layer comprises reverse printing; a secondlayer adjacent the second side of the first layer, constituting an innerlayer of the packaging laminate, comprising a linear low densitypolyethylene (LLDPE) resin with a coextruded ethyl vinyl alcohol (EVOH)film barrier, and a metallocene catalyst present in an amount of about 5to 33 percent by weight of the second layer; and a degassing valveremovably attached to the container body, wherein the degassing valvecomprises HDPE, and wherein the first layer has a thickness of about 0.5MTh to about 1.5 MTh and the second layer has a thickness of about 2 MThto about 5 MIL.
 2. The packaging container of claim 1, wherein the HDPEcomprises between 75 and 100 percent by weight of the first layer. 3.The packaging container of claim 2, wherein the first layer furthercomprises octene in an amount of 8 to 20 percent by weight of the firstlayer.
 4. The packaging container of claim 1, wherein the first layerfurther comprises a calcium carbonate filler.
 5. A packaging container,comprising: a container body formed of a packaging laminate, wherein thepackaging laminate comprises: a print layer, constituting an outer layerof the packaging laminate, comprising a high density polyethylene (HDPE)resin, wherein the print layer comprises a first side and second side,and wherein the second side comprises reverse printing, a core layeradjacent the second side of the print layer, constituting anintermediate layer of the packaging laminate, comprising a HDPE resin, alinear low density polyethylene (LLDPE) resin, a low densitypolyethylene (LDPE) resin, or combinations thereof, and a sealant layer,constituting an inner layer of the packaging laminate, comprising aLLDPE resin with a coextruded ethyl vinyl alcohol (EVOH) film barrier,EVOH compatibilizer, and a catalyst present in an amount of about 5 to33 percent by weight of the sealant layer, and a degassing valveremovably attached to a wall of the container body, and wherein theprint layer has a thickness of about 0.8 MTh to about 2.5 MIL, thesealant layer has a thickness of about 2 MTh to about 4 MIL, and thecore layer has a thickness of about 0.4 MTh to about 4 MTh.
 6. Thepackaging container of claim 5, wherein the EVOH compatibilizer ispresent in a 1:1 ratio with the EVOH film barrier.
 7. The packagingcontainer of claim 5, wherein the catalyst is a metallocene catalyst. 8.The packaging container of claim 5, wherein the print layer has athickness of about 0.8 MTh to about 1 MTh.
 9. The packaging container ofclaim 5, wherein the HDPE comprises at least 40 percent by weight of theprint layer.
 10. The packaging container of claim 5, wherein each layerof the packaging laminate has a haze value of about 10 percent to about60 percent.
 11. The packaging container of claim 5, wherein thepackaging container has a percentage of residual oxygen of about 2.65percent or less over a time period of 52 weeks.
 12. The packagingcontainer of claim 5, wherein the sealant layer further comprises a HDPEresin or a LDPE resin.
 13. The packaging container of claim 5, whereinthe sealant layer further comprises or about 8 percent to about 20percent weight of an ionomer.
 14. A packaging container, comprising: acontainer body formed of a packaging laminate, wherein the packaginglaminate comprises: an outer layer comprising a high densitypolyethylene (HDPE) resin, wherein the outer layer comprises a firstside and a second side, and wherein the second side comprises reverseprinting; an intermediate layer adjacent the second side of the outerlayer comprising a HDPE resin, a linear low density polyethylene (LLDPE)resin, a low density polyethylene (LDPE) resin, or combinations thereof;and a sealant layer, constituting an inner layer of the packaginglaminate, comprising a LLDPE resin with a compatibilizer, ethyl vinylalcohol (EVOH), and a catalyst present in an amount of about 5 to 33percent by weight of the sealant layer, wherein the compatibilizer andEVOH are present in a 1:1 ratio, and a degassing valve removablyattached to the container body, wherein the degassing valve comprisesHDPE, wherein the outer layer has a thickness of about 0.8 MTh to about1.25 MTh, the sealant layer has a thickness of about 2 MTh to about 3.5MTh, and the intermediate layer has a thickness of about 1 MTh to about3 MTh.
 15. The packaging container of claim 14, wherein the packagingcontainer is recyclable to the same extent as #2 HDPE film.
 16. Thepackaging container of claim 5, wherein the packaging container isrecyclable to the same extent as #2 HDPE film.
 17. The packagingcontainer of claim 1, wherein the second layer further comprises an EVOHcompatibilizer.
 18. The packaging container of claim 17, wherein theEVOH compatibilizer is present in a 1:1 ratio with the EVOH film barrierand comprises between about 2 and 15 percent of the total weight of thesecond layer.
 19. The packaging container of claim 14, wherein thecatalyst is a metallocene catalyst.